Split ply tires and bead area monocomponents

ABSTRACT

An intermediate article of manufacture formed as a first stage bead area subassembly for a split ply pneumatic tire carcass is disclosed. The bead area subassembly has an annular bead core; a bead apex; a ply strip; and preferably a sidewall affixed to the ply strip. The subassembly is formed into a disk-shaped bead area monocomponent. The ply strip is wrapped about the bead core and the apex to form a ply turnup and both the ply strip and the ply turnup extend radially outwardly from the bead core. The bead area subassembly when formed into the disk-shaped bead area monocomponent is placed on an annular holder device.

RELATED APPLICATIONS

The present invention is a division of U.S. application Ser. No.13/206,603 filed on Aug. 10, 2011 entitled “SPLIT PLY TIRES AND BEADAREA MONOCOMPONENTS”.

TECHNICAL FIELD

The present invention relates to pneumatic tires generally, morespecifically to split ply tire constructions and their method ofmanufacture.

BACKGROUND OF THE INVENTION

A conventional radial ply tire has a single carcass ply extendingbetween a pair of axially spaced bead cores which is wrapped about eachbead core having axially outer ply turnup ends. This construction hasthe main working part of the ply turned inside of a bead apex forcing acurvature in the ply path when the tire is mounted onto a rim. Thiscurvature gives the radial tire a fat bulging appearance in the tirefootprint when under load.

Attempts to avoid this sidewall curvature change about the bead and beadapex have led some to attempt a ply path that wraps about the bead andhas the turnup end wrap inside of the bead and bead apex. In thisconstruction the turnups are positioned inside the beads and the plypath avoids the normal curvature change. This provides a betterperforming tire in terms of bead area durability and overall tireperformance.

Unfortunately, such a tire when made with a single carcass ply isdifficult to mass produce because the inside turnups are not conduciveto conventional tire building.

In U.S. Pat. No. 6,913,052 B2 assigned to The Goodyear Tire & RubberCo., a split ply structure and method of manufacture was proposedwherein inextensible steel plies could be made with inside turnups. Theadvantages being improved bead durability and significantly reducedweight reduction. In this patent the method of building the tire havinga carcass assembly having a pair of bead cores and a radial plyreinforcing structure has the steps of cylindrically applying a pair ofradial cord reinforced sidewall plies, each sidewall ply having a widthWp; setting one bead core over each sidewall ply and fixing the axialspacing between the bead cores at a distance L; applying a crown plyhaving a width WC, WC being less than the distance L and the crown plybeing interposed between and spaced from each sidewall ply when applied;turning up each sidewall ply to fold over and overlap the lateral edgesof the crown ply; moving the carcass assembly axially inwardly whileshaping the carcass assembly toroidially to form ply turnups axiallyinward of the bead cores. The step of stitching the overlap of thesidewall plies to the crown ply is recommended. Once toroidially shapedthe method can further include applying a belt reinforcing structure tothe toroidially shaped carcass, the first belt reinforcing layer havinga width WB, the first belt layer overlaps the radially outer ends of thesidewall plies. Then an additional one or more belt reinforcing layerscan be applied to the carcass as well as applying the tread.

This method of cylindrically forming the split ply carcass as a completestage 1 assembly allowed the second stage toroidal assembly of the beltsand tread similar to conventional tire building.

The method and resultant prior art tire while novel did not take fulladvantage of the split ply features and as a practical matter was notthat different from conventional tire building.

The present invention discloses a new and unique assembly of a bead areamonocomponent that can be made as an intermediate article of manufacturein a first stage building method and then can be assembled later as anintermediate article of manufacture into a second stage toroidaly shapedgreen split ply carcass assembly along with the belt structure and treadto form an uncured tire assembly.

The present invention has the objectives of allowing a simplifiedassembly of the bead area monocomponents; provide allowance for a rangeof tire sizes to be made from one size of the monocomponent; the methodemploys a molded hub device for bead carrying and centering as well asholding the completed intermediate articles of manufacture for storageonce formed as a subassembly. These and other objectives are disclosedas follows.

SUMMARY OF THE INVENTION

An intermediate article of manufacture formed as a first stage bead areasubassembly for a split ply pneumatic tire carcass is disclosed. Thebead area subassembly has an annular bead core; a bead apex; a plystrip; and preferably a sidewall affixed to the ply strip. Thesubassembly is formed into a disk-shaped bead area monocomponent. Theply strip is wrapped about the bead core and the apex to form a plyturnup and both the ply strip and the ply turnup extend radiallyoutwardly from the bead core. The bead area subassembly when formed intothe disk-shaped bead area monocomponent is placed on an annular holderdevice. The combination of the bead area monocomponent and the holderdevice can be stacked for storage and latter assembly into a split plycarcass. Preferably, the ply turnup can be oriented extending inside oraxially inward of the bead core on final assembly to form a split plytire having axially inside turnups. In the preferred embodiment the plystrip is reinforced by radially extending ply cords.

The assembly can be used in a split ply pneumatic tire. The tire has aninner liner; a pair of bead area monocomponents pre-formed as adisk-shaped single subassembly, a crown ply overlapping and extendingover ends of ply strips of each monocomponent, the crown ply and plystrip ends being stitched together; a belt reinforcing structureoverlaying the crown ply and ends of the ply strips to form the splitply casing; and a tread overlaying the split ply casing. Each bead areamonocomponent includes a bead core, a bead apex, a gum chafer, a plystrip and a sidewall, the pair of bead area monocomponents overlayingthe inner liner and being spaced to form the side portions of a splitply carcass. The monocomponents are identical as formed and onemonocomponent is rotated 180 degrees to form an opposite side of thesplit ply carcass. Each of the ply turnups is preferably oriented to beaxially inside the tire carcass relative to the split ply, bead core andbead apex and the split plies are, preferably, reinforced by radiallyextending cords.

A method of forming an article of manufacture formed as a first stagebead area subassembly for a split ply pneumatic tire carcass has thesteps of: providing a first stage building drum having a singleinflatable turnup bladder, a single set of bead locks and an expandableset of center segments and a plurality of separate molded hubs fordelivering the beads and removing and storing the finished subassembly;applying a gum chafer strip cylindrically onto the bladder turnupadjacent the expandable set of center segments; applying a ply stripcylindrically over the gum chafer strip; delivering a bead core held bya molded hub and positioning the bead core overlaying the gum chaferstrip and the ply strip over the single set of bead locks; clamping thebead core and removing the molded hub; expanding the set of expandablecenter segments turning radially upwardly a portion of the ply strip;applying a bead apex against the bead core and the turned up portion ofthe ply strip; inflating the turnup bladder moving the remaining portionof the ply strip about the bead core and bead apex and ply strip turnupto form a radially extending disk-shaped bead area monocomponent. Themethod of forming an article of manufacture formed as a first stage beadarea subassembly for a split ply pneumatic tire carcass further mayinclude the step of applying a sidewall against the ply strip tocomplete the bead area monocomponent. Preferably, the apex is appliedfrom a gear pump and extruded onto the bead core and turnup andsimilarly the sidewall is applied from a gear pump and extruded onto thesplit ply. Alternatively, the apex and sidewall can be applied from cutto length strips.

The method forming an article of manufacture formed as a first stagebead area subassembly for a split ply pneumatic tire carcass further mayhave the steps of moving the molded hub over the first stage buildingdrum to attach or hold the finished bead area monocomponent; andremoving the molded hub with attached bead area monocomponent andstacking the molded hub with an attached bead area monocomponent intostacks for storage and latter assembly.

Definitions

As used herein and in the claims,

“Aspect Ratio” means the ratio of its section height to its sectionwidth.

“Axial” and “axially” means the lines or directions that are parallel tothe axis of rotation of the tire.

“Bead” or “Bead Core” means generally that part of the tire comprisingan annular tensile member, the radially inner beads are associated withholding the tire to the rim being wrapped by ply cords and shaped, withor without other reinforcement elements such as flippers, chippers,apexes or fillers, toe guards and chafers.

“Belt Structure” or “Reinforcing Belts” means at least two annularlayers or plies of parallel cords, woven or unwoven, underlying thetread, unanchored to the bead, and having both left and right cordangles in the range from 17 degrees to 27 degrees with respect to theequatorial plane of the tire.

“Circumferential” means lines or directions extending along theperimeter of the surface of the annular tread perpendicular to the axialdirection.

“Carcass” means the tire structure apart from the belt structure, tread,undertread, over the plies, but including the beads.

“Casing” means the carcass, belt structure, beads, sidewalls and allother components of the tire excepting the tread and undertread.

“Chafers” refers to narrow strips of material placed around the outsideof the bead to protect cord plies from the rim, distribute flexing abovethe rim.

“Cord” means one of the reinforcement strands of which the plies in thetire are comprised.

“Equatorial Plane (EP)” means the plane perpendicular to the tire's axisof rotation and passing through the center of its tread.

“Footprint” means the contact patch or area of contact of the tire treadwith a flat surface at zero speed and under normal load and pressure.

“Inner liner” means the layer or layers of elastomer or other materialthat form the inside surface of a tubeless tire and that contain theinflating fluid within the tire.

“Normal Inflation Pressure” means the specific design inflation pressureand load assigned by the appropriate standards organization for theservice condition for the tire.

“Normal Load” means the specific design inflation pressure and loadassigned by the appropriate standards organization for the servicecondition for the tire.

“Ply” means a layer of rubber-coated parallel cords.

“Pneumatic tire” means a laminated mechanical device of generallytoroidal shape (usually an open-torus) having bead cores and a tread andmade of rubber, chemicals, fabric and steel or other materials. Whenmounted on the wheel of a motor vehicle, the tire through its treadprovides traction and contains the fluid that sustains the vehicle load.

“Radial” and “radially” mean directions radially toward or away from theaxis of rotation of the tire.

“Radial Ply Tire” means a belted or circumferentially-restrictedpneumatic tire in which at least one ply has cords which extend frombead to bead are laid at cord angles between 65 degrees and 90 degreeswith respect to the equatorial plane of the tire.

“Section Height” means the radial distance from the nominal rim diameterto the outer diameter of the tire at its equatorial plane.

“Section Width” means the maximum linear distance parallel to the axisof the tire and between the exterior of its sidewalls when and after ithas been inflated at normal pressure for 24 hours, but unloaded,excluding elevations of the sidewalls due to labeling, decoration orprotective bands.

“Sidewall” means that component which comprises a portion of the outsidesurface of a tire between the tread and the be

“Shoulder” means the upper portion of sidewall just below the treadedge.

“Sidewall” means that portion of a tire between the tread and the bead.

“Tire industry standard size” refers to the series of letters andnumbers used by tire manufacturers to define a tire's characteristics.The series includes such factors as tire width, aspect ratio (height towidth), radial/bias type, rim diameter, speed rating, and load rating.

“Tread” means a molded rubber component which, when bonded to a tirecasing, includes that portion of the tire that comes into contact withthe road when the tire is normally inflated and under normal load.

“Tread Width or Tread Arc Width” means the arc length of theroad-contacting tread surface in the axial direction, that is, in aplane parallel to the axis of rotation of the tire.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe detailed description given below, serve to explain the invention.

FIGS. 1-5 are partial cut-away perspective views of a simplified firststage building drum for building the disk-shaped bead area monocomponentof the present invention.

FIG. 1 shows the gum chafer strip positioned under the ply strip withthe bead core affixed to a molded holder being positioned in place asshown.

FIG. 2 shows the bead holder withdrawn and removed from the buildingdrum.

FIG. 2A shows the exemplary bead lock fingers added to the view of thebuilding drum showing how the bead core is locked onto the buildingdrum.

FIG. 3 shows the radially expandable drum center segments expandedcausing the turnup to fold radially upwardly and an apex strip beingextruded onto the bead core and against the turnup.

FIG. 4 is a schematic view of the turnup bladder being inflated causingthe ply strip to be oriented radially outwardly thus shaping the beadarea monocomponent into a disk-shape.

FIG. 5 is a schematic view of a sidewall being formed against the plystrip completing the disk-shaped bead area monocomponent.

FIG. 6 is a cross sectional view of the disk-shaped monocomponent madeaccording to the present invention.

FIG. 7 is a partial view of the molded hub shown holding a bead core.

FIG. 8 shows a stack of molded hubs.

FIG. 9 shows how the disk-shaped monocomponent can be held by the moldhub.

FIG. 10 shows the molded hub placing the disk-shaped monocomponent ontoa second stage building machine.

FIG. 11 is the schematic cross sectional view of a split ply carcasshaving a pair of the disk-shaped monocomponents of the presentinvention.

FIG. 12A is a schematic view of an unvulcanized split ply casing withbelt reinforcement applied onto the carcass.

FIG. 12B is the split ply tire schematic with a tread added to thecasing to complete the assembly.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 6, a cross sectional view of the disk-shaped beadarea monocomponent made according to the present invention isillustrated. As shown, the monocomponent 10 has a bead core 20. The beadcore 20 is made of substantially inextensible wires wrapped around toform an annular ring. Directly above the bead core 20 is an elastomericapex 30. The apex 30, shown in a somewhat triangular form, is positionedand provides an elastomeric spacer between the ply strip 12 and the plyturnups 14 as illustrated. The ply turnup 14 as shown extends to aturnup end 14A which is stitched directly onto the working portion oroutside ply portion 12A of the ply strip 12. The ply strip 12 wrappingabout the bead core 20 as shown provides the opportunity to have aninside ply ending or turnup 14 relative to the bead core 20. On theoutside of the ply strip 12 is the working portion of the ply whichextends to a radially outer end 13 as illustrated and affixed to theouter surface of the ply strip 12 is a rubber or elastomeric sidewallportion 40 which extends along a portion of the outside of the ply strip12 downward to the gum chafer 11. The gum chafer 11 is applied to theply strip 12 and both wrap directly under the bead core 20 up and aroundthe bead as illustrated. The gum chafer 11 provides a durable rubberelement to prevent rim chaffing when mounted on a tire rim. Thesecomponents as shown are assembled and provided as a simple relativelyflat disk-shaped bead area monocomponent for use in making a split plycarcass for a split ply tire assembly.

With reference to FIGS. 10 and 11 a schematic cross sectional view of asplit ply carcass is shown using a pair of the disk-shapedmonocomponents 10 of the present invention. The pair of disk-shapedmonocomponents 10 preferably is positioned on each side of a secondstage building drum 90 on a radially expandable mandrel 92 overlying asubstantially air impervious inner liner 15 and the radially outer plyendings 13 are covered by a reinforcement crown ply 16. As shown thesplit plies 12 preferably are reinforced by cords 7, the cords 7 can betextile, rayon, polyester, aramid, or alternatively can be made out ofsteel if so desired. When so produced the monocomponent 10 is positionedsuch that the turnup 14 is provided axially inward of the bead core 20in such a fashion that the working ply portion 12A of the ply strip 12is on the axially outer side of the tire relative to the bead cores 20and extends upward to the crown ply. The positioned crown ply 16 isstitched directly onto the ends of the monocomponent 10 at the ply stripending 13 in such a fashion that the crown ply 16 extends from both plystrips 12 to form the split ply carcass structure as shown.

Once the carcass is assembled as shown in FIG. 11 using the pair ofdisk-shaped monocomponents 10 of the present invention, it can be formedinto a split ply casing with the addition of belt reinforcement plies17, 18 applied onto the carcass overlaying the crown ply 16 and the ends13 of each of the ply strips 12. This is shown in FIG. 12A. Withreference to FIG. 12B once the belt reinforcement plies 17, 18 have beenadded to form a casing, the entire assembly can be completed by theapplication of a tread 19 applied over the belt reinforcements 17, 18and extending to the sidewall 40 of the monocomponent 10 as illustrated.As can be easily appreciated, the bead area monocomponent 10 beingformed in a flat disk-shape makes it quite convenient for producing atire such that inside turnups 14 can be provided on a split ply carcassin such a way that all of the sidewall components including the bead 20,gum chafer 11, sidewall 40, apex 30 and the sidewall split ply strip 12can be provided as a single unitary component. By having one of themonocomponents 10 rotated 180 degrees relative to the other enables theopposite side of the tire to be built such that an inside turnup is alsoachieved on the opposite side of the tire casing using the sameidentical monocomponent 10.

One of the advantages of the disk-shaped bead area monocomponent 10 asillustrated is that a variety of tire sizes can be made using a singlecomponent structure. This is possible because the width of the tire canbe changed by providing a longer or wider width crown ply 16 such thatthe beads can be moved outwardly and wider tires can be produced.Alternatively, a narrower crown ply will produce a narrower tireassuming the sidewalls all have the same length. Alternatively, the tirecan be produced even with different sidewall heights using the samecomponents simply by increasing or reducing the amount of overlapbetween the crown ply and the sidewall ply if so desired. While this isnormally not preferred due to wastage, in some cases where an overextension of overlap material is used it is possible to make tires ofvarying widths and sidewall dimensions simply by varying the amount oftread rubber that is applied adjacent to the sidewall. In such a fashionthat an upper portion of the tread may extend downward a litter fartherthan normal and this would enable the assembly to produce a variety ofsizes of both different widths and different heights. It is believedpreferable that only tires of different widths be constructed using thesame sidewall lengths in that specifically designed tires havingadditional sidewall rubber can be applied for taller tires if so neededor if a lower aspect ratio shorter tire sidewall is needed less sidewallrubber can be applied. In this fashion it is possible that the sidewallrubber can be applied at the second stage and that the monocomponent 10could be made without including the sidewall rubber, in that case tiresof any size could be produced using a single monocomponent 10 in adisk-shape as illustrated. In that case the sidewall rubber would beapplied as the second stage of the building process. While this is notthe preferred embodiment, the preferred embodiment method of assemblyincludes the use of the sidewall 40 as part of the first stage buildingwhich will be described as follows in reference to FIGS. 1-5.

In order to make the disk-shaped monocomponent 10 of the presentinvention, it is important to use a modified or simplified first stagebuilding drum 50. The method of assembly is shown in FIGS. 1-5 whereinthe disk-shaped bead area monocomponent 10 of the present invention isshown being assembled at a modified first stage building drum 50. Aunique feature of this first stage assembly is that the building drum 50is only basically half of a normal or conventional first stage buildingdrum 50 in that it has only one set of drum center segments 51 that areradially expandable and has a single turnup bag or bladder 52 attachedto the first stage building drum 50 and one set of bead locks 54. Thebead locks are not shown in FIG. 1, however are shown in FIG. 2A. Thebead locks 54 are expandable and retractable to provide a way ofsecuring the bead 20 when the bead core 20 is positioned over the firststage building drum 50. As shown, the bead core 20 is delivered over theturnup bladder 52 as shown in FIG. 1 by means of a molded hub 2, themolded hub 2 can be moved robotically over the bead lock area as shownin FIG. 2A. When positioned the molded hub 2 can hold the bead core 20which is made substantially of steel wires by using a magnetic elementwithin the bead holder 2 or alternatively can use pins to support thebead core 20. During assembly, the bead core 20 is moved into positionover both a previously applied cylindrical gum strip 11 which is coveredby a ply strip 12 has been cylindrically applied. As shown in FIG. 1,the gum strip 11 is positioned somewhat centrally under the position ofthe bead core 20 and the ply strip 12 is positioned such that a portion14 of the ply strip 12 extends over the radially expandable drum centersegment 51 and another portion 13 of the ply strip 12 extends over theinflatable bladder 52 as shown in FIG. 1. The portion 14 of the plystrip 12 that extends over the radially expandable center segments 51forms a ply turnup 14 as will be discussed later. Once the bead holder 2has moved the bead core 20 into position over the cylindrically formedcomponents 11 and 12 already applied to the first stage building drum50, as shown in FIG. 2A, the bead locks 54 can move out radially lockingthe bead core 20 into position. At that point, the bead holder 2 isremoved. Once the bead core 20 is locked in place, the radiallyexpandable center segments 51 are radially moved outwardly as shown inFIG. 3, when this occurs the turnup 14 is formed oriented vertically asillustrated extending out radially from the bead core 20. As shown inFIG. 3, a gear pump 70 with a nozzle 72 is shown positioned feedingelastomeric material to form a triangular shaped bead apex 30 directlyonto the bead core 20 and against the turnup 14. Alternatively, thisbead apex 30 can be pre-formed as a strip and simply positioned onto thebead core 20 against the turnup 14 if so desired without applying it inthis hot form method shown using the gear pump 70 and extruder. Thisassembly has now created the ply strip 12 with a gum strip 11 and anapex 30 and a bead core 20. In FIG. 4 the turnup bag or bladder 52 isinflated and the remaining portion of the ply strip 12 is pushed againstthe bead core 20 and the apex 30 and extends radially outwardly asillustrated. When this occurs, the bead area monocomponent 10 assemblyis virtually complete as a single piece disk-shaped bead areamonocomponent 10. As shown in FIG. 5, additionally a sidewall rubber canbe applied to this disk-shaped bead area monocomponent 10 as shown. Inthis case a gear pump 80 with an extruder nozzle 82 is shown positionedin such a fashion to deliver sidewall rubber 40 along the side of aportion of the ply strip 12. This hot formed sidewall strip 40 is thenadhered directly onto the monocomponent 10 as illustrated. Once thisassembly is completed the monocomponent 10 can be removed from the firststage building drum 50.

To remove this completed assembly of the monocomponent 10, the moldedhub 2 is brought back into position over the first stage building drum50, bead locks 54 are retracted and the bead released and the molded hub2 can magnetically or by the use of pins grab the monocomponent 10 insuch a fashion that it can be withdrawn over the first stage buildingdrum 50 and held as illustrated in FIG. 9.

As shown in FIGS. 7 and 8, the molded hub 2 is shown in a crosssectional view holding onto a bead core 20. The bead core 20 can be heldmagnetically or by the use of pins that will center the bead core 20relative to the molded hub 2. The molded hub 2 acts as a bead holder inthe first stage building process. As shown it has an external groove 3that can register on centering the yokes on building machines. Thesecentering yokes are fundamentally robotic pieces of equipment that movethe molded hub 2 into position over the bead locks 54. Although, notillustrated, these centering yokes are common features commonly used onfirst stage building machines. As shown by providing the molded hubs 2with a projecting portion 5 on one side of the external groove 3 and arecess 4 on the opposite side, it is possible to stack the molded hubs 2in such a fashion that they can hold a plurality of bead cores 20 in astacked fashion as shown in FIG. 8. This stacking of the bead cores 20enables a plurality of bead cores 20 to be in position ready to bebrought to the modified first stage building machine 50.

Once the monocomponent 10 is completed, the molding hub 2 without beadcores 20 can be used as a storage device for the monocomponents 10, assuch when the monocomponent 10 is completed the molded hub 2 is put backover the first stage building machine 50 and it can capture themonocomponent 10 either magnetically or with the use of pins and bring amonocomponent 10 off of a first stage building machine 50 where it canbe stacked for storage. These monocomponents 10 provide all the sidewallfeatures necessary to build a split ply pneumatic tire as previouslydiscussed. Once completed, these flat disk-shaped monocomponents 10 canbe stored and brought into production to make a finished product asrequired.

While split tires are known, and the use of split ply tires with insideturnups are also known in the prior art, it is believed that such amanufacture of disk-shaped monocomponents has never been attempted. Thisprovision of making the monocomponent into a disk-shape such that it issuitable for use in the second stage building means that all thecomponents necessary to build the sidewall of a tire including the gumchafer 11, the bead core 20, the apex 30, the ply turnup 14, sidewallply 12 and sidewall rubber 40 are all pre-assembled into a singlemonocomponent 10. Accordingly while bringing this single monocomponent10 to a second stage building machine as previously discussed, the onlysteps left are to provide a center crown ply 16 that extends between twoopposing monocomponents 10 with the ends 12 stitched and this can bedone in a radially and toroidaly expanded condition such that the plystrips are stitched about an expandable toroidal mandrel and asstitched, are stitched in a fashion most closely replicating thefinished product. Once this is accomplished the belt reinforcingstructure 17, 18 can be overlayed over the crown center ply 16 and thestitched ends 13 of the ply strips 12 such that a secure assembled splitply casing has been constructed. Once that is accomplished, the tread 19can be applied onto the casing and the tread 19 has lateral ends thatwill extend to the sidewall rubber 40 on each side of the tirecompleting the split ply unvulcanized green tire ready for molding. Thisgreatly simplifies the production steps required to produce such a tireand as such can reduce the cost dramatically in the production of such atire. The advantage is that the turnups 14 are inside and that bothsides of the tire are made from two identical components, one beingflipped 180 degrees relative to the other to enable the ply turnups 14to be positioned inwardly on both sides of the tire 100. Once this isaccomplished, these components can make a tire 100 with improved beaddurability and handling characteristics. While shown the split plydisk-shaped monocomponent 10 is shown utilizing a radial ply strip 12reinforced by radially extending ply cords 7 which can be textile,synthetic, steel or any other material used in the construction ofcarcass plies. Alternatively, other angular orientations can beattempted in the sidewall area of the split ply 12 if so desired.Similarly while the tire 100 is shown as a single ply reinforcement, itis possible to make a bias tire in this fashion by simply providing twolayers of ply strips 12 if so desired. In doing so the two layers of plystrips could have opposing angles, however they would be provided in thefirst stage building as shown in multiple layers as shown in FIG. 1, butwith two layers. While not illustrated, it is important to understandthat a bias tire could be made in this fashion. While this is notpreferred due to the added cost, it is important to note that more thanone ply strip can be added if more reinforcement is needed in thesidewall area. This is important in that elastomeric material could bepositioned between the two ply strips to provide a limited runflatcapability if so desired. These and other features are possible with theuse of the disk-shaped monocomponent 10 as described and shown herein.

The invention has been described with reference to a best mode.Obviously, modifications and alterations will occur to others uponreading and understanding of this specification. It is intended toinclude all such modifications and alterations in so far as they comewithin the scope of the appended claims or the equivalents thereof.

What is claimed is:
 1. A method of forming an article of manufactureformed as a first stage bead area subassembly for a split ply pneumatictire carcass, the method comprising the steps of: providing a firststage building drum having a single inflatable turnup bladder, one setof bead locks and one expandable set of drum center segments and aseparate molded hub for delivering a bead core and removing and storingthe finished subassembly; applying a gum chafer strip cylindrically ontothe inflatable turnup bladder adjacent the one expandable set of drumcenter segments; applying a ply strip cylindrically over the gum chaferstrip; delivering the bead core held by separate molded hub andpositioning the bead core overlaying the gum chafer strip and the plystrip over the single set of bead locks; clamping the bead core andremoving the molded hub; expanding the set of expandable center segmentsturning radially upwardly a portion of the ply strip; applying a beadapex against the bead core and the turned up portion of the ply strip;inflating the turnup bladder moving a remaining portion of the ply stripabout the bead core and bead apex and ply strip turnup to form the firststage bead area subassembly for a split ply tire carcass configured as aradially extending disk-shaped bead area monocomponent.
 2. The method offorming an article of manufacture formed as a first stage bead areasubassembly for a split ply pneumatic tire carcass of claim 1 furthercomprises: applying a sidewall against the ply strip of the bead areamonocomponent to complete the first stage bead area subassembly.
 3. Themethod forming an article of manufacture formed as a first stage beadarea subassembly for a split ply pneumatic tire carcass of claim 1wherein the apex is applied from a gear pump and extruded onto the beadcore and turnup.
 4. The method forming an article of manufacture formedas a first stage bead area subassembly for a split ply pneumatic tirecarcass of claim 2 wherein the sidewall is applied from a gear pump andextruded onto the ply strip.
 5. The method forming an article ofmanufacture formed as a first stage bead area subassembly for a splitply pneumatic tire carcass of claim 2 further comprises the steps of:moving the molded hub over the first stage building drum to attach thefirst stage bead area subassembly configured as the radially extendingdisk-shaped bead area monocomponent; removing the molded hub with theattached first stage bead area subassembly configured as the radiallyextending disk-shaped bead area monocomponent from the first stagebuilding drum.
 6. The method forming an article of manufacture formed asa first stage bead area subassembly for a split ply pneumatic tirecarcass of claim 5 further comprises the step of: stacking the moldedhub with the attached first stage bead area subassembly configured asthe radially extending disk-shaped bead area monocomponent onto a stackfor storage and latter assembly.